Conrad, did you have a look at ibuild, the LiveCD generator? It seem to be the tool of my dreams, but I do not know if it actually work or not. Check out <URL:http://bugs.debian.org/cgi-bin/bugreport.cgi?bug=292222> and <URL:http://ibuild.livecd.net/>. Is this an usable tool? CC to the list, as I know several people here are interested in the same issue. :)